Bagless Dustcup

ABSTRACT

A bagless vacuum cleaner system dustcup assembly and method for using said system with a vacuum cleaner apparatus to separate dirt from a mixture of dirt and air inducted into said vacuum cleaner apparatus. Said bagless vacuum cleaner system generally comprises a dustcup assembly, a handle assembly and a motor intake adaptor.

This application is a continuation of U.S. application Ser. No.12/206,259 filed Sep. 8, 2008, now U.S. Pat. No. 7,628,832, which is acontinuation of U.S. application Ser. No. 11/617,827 filed Dec. 29,2006, now U.S. Pat. No. 7,422,614, which is a continuation of U.S.application Ser. No. 11/035,413 filed Jan. 14, 2005, now U.S. Pat. No.7,163,568, which is a continuation of U.S. application Ser. No.10/429,298, filed May 5, 2003, now U.S. Pat. No. 6,863,702, which is acontinuation of U.S. application Ser. No. 09/759,396, filed Jan. 12,2001, now U.S. Pat. No. 6,558,453, which claims the benefit of U.S.Provisional Application No. 60/176,356, filed Jan. 14, 2000.

FIELD OF THE INVENTION

The present invention relates to vacuum cleaners, and more particularly,to a bagless dust cup assembly to be used in lieu of a disposable dirtcollection bag with an upright vacuum cleaner apparatus.

BACKGROUND OF THE INVENTION

The present invention is directed toward an improved air/dirt separationsystem for an upright vacuum cleaner. The invention is further directedtoward an assembly that may be retrofitted into an existing bag-styleupright cleaner. The assembly according to the invention replaces adisposable bag system with an easy-empty permanent dustcup and cleanablepermanent filter. Although the system successfully supplants thethrowaway dustbag in this retro-fit application, the broader scope ofthe invention contemplates creation of an entirely new vacuum systemthat is dedicated to the bagless concept. Alternatively, by substitutionof components, it is contemplated that the assembly of the presentinvention may be used to configure an upright vacuum cleaner that isadapted for either bag or bagless use.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 a is a front elevational view of a vacuum cleaner according tothe present invention;

FIG. 1 b is a cross sectional view of the cleaner as seen along line B-Bof FIG. 1 a;

FIG. 2 a is a front elevational view of a dustcup of the cleaner;

FIG. 2 b is a rear and bottom perspective view of the dustcup;

FIG. 2 c is a top and front perspective view of the dustcup;

FIG. 3 a shows a top perspective view of the filter assembly of thepresent invention;

FIG. 3 b shows a side and bottom perspective view of the filter assemblyand the cyclone module of the present invention;

FIG. 4 a is a top and side perspective view of a plenum chamber member;

FIG. 4 b is a top perspective view of the plenum chamber member;

FIG. 4 c is a top plan view of the plenum chamber member;

FIG. 4 d is a bottom plan view of the plenum chamber member;

FIG. 5 a is a top and side perspective view of a cyclone module;

FIG. 5 b is a side elevational view of the cyclone module;

FIG. 5 c is a top plan view of the cyclone module;

FIG. 5 d is a bottom view of the cyclone module;

FIG. 6 is an exploded perspective view of the assembly at the lower endof the handle;

FIG. 7 a is a rear perspective view of a rear handle bracket;

FIG. 7 b is a front perspective view of the rear handle bracket;

FIG. 8 a is a top and front perspective view of the front bracket;

FIG. 8 b is a bottom and rear perspective view of the front bracket;

FIG. 9 a is a top perspective view of a top-hinged support;

FIG. 9 b is a top perspective view of the top-hinged support;

FIG. 9 c is a top perspective view of the top-hinged support;

FIG. 10 is a front perspective view of a cover;

FIG. 11 is a view of the plenum chamber member and the top-hingedsupport connected together, with other portions of the assembly removed;

FIG. 12 a is a top perspective view of the motor intake adaptor;

FIG. 12 b is a bottom perspective view of the motor intake adaptor; and

FIG. 13 is a perspective view of the latch.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The dustcup assembly according to the present invention is used in allupright vacuum cleaner apparatus 100 having a vacuum cleaner baseportion 101, a vacuum cleaner body portion or rear housing 102, and avacuum cleaner upstanding handle 104 (FIGS. 1 a-1 b). The base portion101 includes. a horizontally extending, elongated internal compartment105 that receives a known rotating brush element (not shown) andcooperates with the body portion 102 to receive a known motor. The motorserves as a drive for the rotating brush and for a known suction fan orimpeller. Rotation of the suction fan or impeller creates suction thatis selectively communicated to a conventional hose (not shown), whichmay be operably connected to either the elongated internal compartment105 containing the rotating brush element or to any of a number of knownoff-the-floor cleaning tools (not shown).

The body portion 102 is pivotally connected to the base portion 101 andhas a rotational axis that is coaxial with the motor axis. The bodyportion 102 carries a filter/cyclone module, and has an upstandinghandle 104 secured thereto.

A dustcup 106 (FIGS. 2 a-2 c) is removably secured to the cleaner bodyportion 102. The dustcup 106 is a molded plastic part that is preferablyat least partially transparent, but may also be translucent or opaque.By having at least a part of the dustcup 106 transparent, the amount ofcollected dust can be readily seen by the operator and thereby visuallyindicates when the cup 106 should be emptied.

The dustcup 106 integrally provides and defines a dustcup chamber 108and a dustcup passageway 110. The dustcup chamber 108 is disposed towarda front side of the dustcup 106 and is open at a top section 107 of thedustcup 106 and closed at all other sections thereof. The dustcupchamber 108 receives and retains a dirt/dust mixture inducted into thevacuum cleaner apparatus 100 either by the rotating brush element or byany of the off-floor cleaning tools, and preferably, the dustcup chamber108 has at least a transparent front wall 109. Additionally, the dustcupchamber is provided with a step-like barrier 111 at the base thereof.Dirt-laden air flowing spirally downward impinges against the barrier111 and dirt particles are caused to separate from the air by strikingthe barrier 111. The filter/cyclone module is received by the topsection 107 of the dustcup 106 and communicates with both the dustcupchamber 108 and the dustcup passageway 110.

The dustcup passageway 110 is disposed toward a rear side of the dustcup106 and defines a path for a stream of clean air to flow from an upperend of the dustcup 106 to a lower end of the dustcup 106. The dustcuppassageway 110 serves as a conduit that connects a lower motor inlet(not shown) to an upper plenum chamber 200. In operation, the dustcuppassageway 110 communicates suction from the motor/fan to the dustcup106, as will be apparent from the following description.

A dustcup handle 112 is attached to the front wall 109 of the dustcup106 and provides a means for an operator of the vacuum cleaner apparatus100 to easily grasp and hold or transport the dustcup 106 when it isindependent of the body portion 102.

The dustcup 106 has a generally round or circular top end region 113that assists in receiving a cyclonic module. The inventors have foundthat the circular configuration of the dustcup top end region 113 issuperior to other contours. However, it has also been found that thedustcup 106 may deviate from the round configuration as one movesdownwardly away from the top end without negatively affecting thedirt-separating performance.

As will be described hereinafter, the cyclonic module receives adirt-laden stream of air and separates the dirt from the air. The dirtis retained in the dustcup chamber 108. The dirt-free air is directed tothe motor/fan via the dustcup passageway 110. The cyclonic moduleincludes a filter assembly 114 (FIGS. 3 a-3 b), a plenum chamber member116 (FIGS. 4 a-4 d), and a cyclone module 118 (FIGS. 5 a-5 c).

The filter assembly 114 includes a filter 124 and a cup-like filterreceptacle or holder 126. The filter receptacle 126 removably fastens toand extends downwardly from the cyclone module 118 and has a generallyfrustoconical form.

The filter receptacle 126 is provided with a circular opening 127defined by its large end 128 and is thus adapted to receive and supportthe filter 124. The filter 124 is generally cone-shaped, with an opentop end 129, and is formed from an open cell flexible foam material. Thefilter 124 is slidably inserted into the circular opening 127 of thefilter receptacle 126. The filter receptacle 126 and associated filter124 are adapted to be received by the cyclone module 118. The filterreceptacle 126 is provided at its large open end 128 with a plurality ofmounting hooks 121. The mounting hooks 121 extend upwardly from and arespaced circumferentially about the open end 128. Each of the hooks 121has a circumferentially directed projection 121 a that defines aslot-like void 122 between a bottom edge 121 b of the projection 121 aand the top edge of the open end 128. Each of the mounting hooks 121also has on its vertically oriented outside surface a rib-likeprojection 123. The projection 123, which is situated proximate to theslot-like void 122 defined by each of the hooks 121, extends verticallyacross the outside surface of each of the mounting hooks 121 and workswith the hooks 121 to removably attach the filter assembly 114 to thecyclone module 118 in a manner to be explained in subsequent discussion.In addition to the mounting hooks 121 the filter receptacle 126 is alsoprovided at its large open end with a plurality of bump-like structures125. The bump-like structures 125 extend a relatively short distanceupward from and are spaced circumferentially about the open end 128 andbetween the mounting hooks 121. When the filter assembly 114 is attachedto the cyclone module 118, the bump-like structures 125 engage thecyclone module 118 in a manner that will also be subsequently described.

The filter receptacle 126 is further comprised of a plurality ofelongated, rib-like appendages 191 that extend downwardly from the largeopen end 128 of the receptacle 126. Each of the rib-like appendages 191is angled inwardly relative to the open end 128 and connect at theirlower end to an annular collar 192 that is integrally joined to theperiphery of a flat, circular top portion 193 of a cylindrical lowerportion 194 of the filter receptacle 126. The cylindrical lower portion194 is provided with a series ribs of 195. The ribs 195, which aremolded into the outer surface of the cylindrical lower portion 194,extend vertically along the outer surface and are separated from oneanother in the circumferential direction so as to define a series ofdepressions 196 between the ribs 195. The ribs 195 and the depressions196 cooperate to create a gripping surface that can be grasped by a userof the vacuum cleaner apparatus 100 and to impart rotational movement tothe receptacle 126 for purposes to be subsequently described.

The filter receptacle 126 is further provided with a porous screenelement 197. The screen element 197, which is preferably fabricated frominterwoven nylon filaments, engages the periphery of the large open end128, the rib-like appendages 191 and the annular collar 192 so as toform a permeable barrier between the filter 124 and the air-dirt mixturethat swirls about the interior of the dirtcup chamber 108. The screenelement 197 serves to prevent relatively large dirt particles fromcontacting and adhering to the filter 124.

The cyclone module 118 (FIGS. 5 a-5 c) is disposed beneath the plenumchamber member 116 and is secured to the plenum chamber member 116 via aplurality of upstanding screw-receiving bosses 140. The plenum-chambermember 116 cooperates with the cyclone module 118 to define a peripherallabyrinth or tongue and groove sealing interlock 117 between a loweredge 119 of the plenum chamber member 116 and an upper surface edge 120of the cyclone module 118. This provides a means for positivepositioning or registration between these elements of the assembly andair-tight sealing without the need for additional gaskets. The plenumchamber member 116 is further provided with a handle 115 that isremovably fastened to the top of the plenum chamber member by knownfastening means such as screws (not shown) that are received by thescrew-receiving bosses 140 provided in the cyclone module 118.

The cyclone module 118 includes an upper wall 142 that has a peripheralopening 141 that communicates with a peripheral volute passage 144 of avolute structure 145, and a downwardly-flanged central opening 143around which a plurality of relatively flat, elongated appendages 146downwardly extend. The elongated appendages 146 angle inwardly relativeto the central opening 143 and they are connected at their lower ends toa disk-like portion 139. The appendages 146 and the disk-like portion139 define a frustoconical, cage-like structure 150. The cage-likestructure 150 is dimensionally configured like the inside surface of thefilter 124 and is thus made capable of receiving the filter 124. Thestructure 150 acts both as a support for the filter 124 and as a meansto prevent it from inwardly distorting or collapsing due to negativepressure when the vacuum cleaner apparatus 100 is in operation.

The wall 142 of the cyclone chamber 118 is provided with a firstplurality of arcuate raised structures 153. The structures 153 arearranged about the central opening 143 in a circular pattern and theydefine a first plurality of relatively deep inverted channels 154 thathave openings 155 on the bottom surface 147 of the upper wall 142 andthat further have openings 156 on the vertically extending sides 157 ofthe channels 154.

Additionally, the upper wall 142 of the cyclone chamber 118 is providedwith a second plurality of arcuate raised structures 158. The structures158 are arranged about the central opening 143 and located between thestructures 153 so that the raised structures 158 lie on the same circlethat passes through the raised structures 153. The raised structures 158define a second plurality of inverted channels 159 that are shallowrelative to the inverted channels 154 and that have openings 160 on thebottom surface 147 of the cyclone module 118. Also on the bottom surface147, a pair of rib-like projections 162 and 164 are provided. Theprojection 162 forms a circular arc and lies just radially outside ofthe inverted channels 154 and 159. The projection 164 forms a continuouscircle and is positioned radially between the central opening 143 andthe inverted channels 154 and 159. Both of the rib like projections 162and 164 extend a short distance vertically downward from the bottomsurface 147; however, the rib-like projection 162 extends fartherdownwardly than the rib-like projection 164.

The first plurality of inverted channels 154 and the second plurality ofchannels 159 are also situated on the wall 142 of the cyclone module 118so that the bottom openings 155 receive the mounting hooks 121 of thefilter receptacle 126 and so that the openings 160 receive the bump-likestructures 125 also of the filter receptacle 126. Once the mountinghooks 121 and the bump-like structures 125 are so received by the bottomopenings 155 and 160, they are caused to rotatably move within thechannels 154 and 159 so that, in the case of the mounting hooks 121, thecircumferentially directed projections 121 a and the rib likeprojections 123 are received by the side openings 156 of the channels154 to secure the filter receptacle 126 to cyclone module 118 and sothat, in the case of the bump-like structures 125, the structures 125cause the top 129 of the filter 124, which projects a short distancevertically above the top of the filter receptacle 126, to becomecompressed against the circular rib-like projection 164 and the portionsof the bottom surface 147 of the cyclone module 118, lying radiallyinward and outward of the projection 164. The hooks 121 and thebump-like structures 125 are caused to rotatably move in the abovedescribed fashion when the user of the vacuum cleaner apparatus 100grasps the downwardly extending portion of the filter receptacle 126 andtwists the receptacle 126 in a clockwise direction relative to thebottom surface 147 of the wall 142 of the cyclone module 118. When thereceptacle 126 is so twisted, the bottom edge 121 b of the projection121 a engages the top surface of the upper wall 142 and the rib-likeprojection 123 engages an outer edge of the opening 156 of the invertedchannel 154 to resist rotational movement of the receptacle 126 untilsuch time as the operator desires to remove the receptacle 126 and thefilter 125 from the module 118. It should also be noted that, when theprojections 121 a and the ribs 123 engage the inverted channels 154 andthe wall 142 in the above described manner, a portion of the outsidesurface of the top of the receptacle 126 rests just inside of theprojection 164 an thus provides an outer seal for the filter 124.

The inlet passageway or chimney 130 of the plenum chamber member 116vertically aligns with the peripheral volute opening 141 of the cyclonemodule 118 and serves to introduce dirt-laden air tangentially into thetop of the chamber 108 of the dustcup 106 via the cyclone module 118.The volute structure 145 extends downwardly from the upper wall 142 anddefines the passage 144 that extends spirally downward from the upperwall 142.

Finally, a resilient gasket element 161 is mounted on the lower surface143 of the flange that forms the perimeter of the cyclone module. Thegasket 161 provides the seal between the cyclone module 118 and the topsurface of the dustcup 106.

When the plenum chamber member 116 and the cyclone module 118 areproperly assembled an air space or chamber 200 is provided between thetop wall 147 of the cyclone module 118 and the bottom surface of theplenum chamber member 116. This air space 200 is required in order toallow airflow to communicate between the suction fan and the dustcupintake port.

To complete the adaptation of the dustcup assembly in this retro-fitapplication there is a need for components that will accept the dustcup106 into the existing housing 102 with minimal impact to existingconfiguration and will enhance operator interface. Additionally, inorder to maintain the minimum size of the shipping carton, theupstanding handle 104 is packaged detached from the vacuum body 102. Theupstanding handle 104 includes a peripheral handle rib 165 at the lowerportion thereof. The handle rib 165 locates and retains the componentsthat will ultimately interact with the dustcup 106.

The lower handle assembly 170 (FIG. 6) includes a rear handle bracket171 (FIGS. 7 a-7 b), a front handle bracket 172 (FIGS. 8 a-8 b), atop-hinged support 174 (FIGS. 9 a-9 c), and a top cover 176 (FIG. 10).These components, in conjunction with a latch 178 (FIG. 13) and variousconventional springs and gaskets, define the assembly 170 that ispermanently attached at the base of the upstanding handle 104. When theupstanding handle 104 is mounted to the top of the rear housing 102 bythe operator, the above listed parts of the assembly 170 work in concertwith the dustcup 106, as will be apparent from the following.

To complete the adaptation of the dustcup 106 to the existing uprightrear housing 102 it is necessary to provide means for getting airflowfrom the suction fan into the dustcup passageway 110 that is located atthe rear of the dustcup 106. A motor intake adapter 180 (FIGS. 12 a-12b) provides a transition between the dustcup passageway 110 and thesuction fan. The adaptor 180 is a molded plastic structure having aflat, generally rectangular base portion 181, a walled structure 184extending upwardly from the base portion 181, a thin, vane-likestructure 186 extending upwardly from the base portion 181 and outwardlyfrom a side of the walled structure 184, and a mounting flange 182. Thewalled structure 184 defines a passageway 188 having a top opening 187and a bottom opening 189 that is situated in the base portion 182 of theadaptor 180. The passageway is preferably provided with an open cellfoam filter 190 that serves as a final means to catch any dirt particlesbefore the air stream enters the suction motor. The vane-like structure186 is provided with a semi-circular aperture 185. When installed in thevacuum cleaner apparatus 100, the bottom side of the base portion 181and the opening 189 of the passageway 188 are situated at the opening ofthe intake of the suction motor, the vane-like structure 186 engages analready existing post-like projection within the rear housing 102, andthe mounting flange 182 is captured by a preexisting rib structureinside the rear housing 102 and the motor cover. When the motor cover isattached to the rear housing 102, the flange 182 of the adapter 180 istrapped between the suction motor intake and the preexisting ribstructure of the housing 102 and a seal is created between the face ofthe motor intake and the motor intake adapter 180. A molded gasket (notshown) is positioned on the top perimeter surface of a walled structure184 and acts as the resilient seal that is compressed by the lowerflange of the dustcup passageway 110 when the dustcup 106 is pivotedinto its working position partially recessed inside the rear housing102.

In operation, with dustcup assembly installed, motor intake to suctionfan is in fluid communication with a suction nozzle (not shown).Negative pressure is generated by the suction fan and pulls air throughthe system. Dirt mixed with air enters the nozzle, travels through thehose and continues through the hose connector. The hose connector ismounted to a chimney extension 175 on the tophinged support 174. Airflows through the inlet 131 on the plenum chamber and into the top ofthe cyclone module intake port 143 and is caused to bend 90 degrees bythe volute 145 and internal rib construction.

Air exits the cyclone inlet and enters the top of circular portion ofthe chamber 108 of the dustcup 106 in a path tangential to the innerwall. After traveling about halfway around the inside circumference ofthe dustcup chamber 108, the air/dirt mixture encounters the helicaldownward-ramped spiral 149 of the base of the cyclone intake. As theair/dirt mixture encounters the spiral 149, the mixture is encouraged totravel axially downward while still maintaining the centrifugal forcesof high speed rotation that effectively separates the large particlematter from the air flow. Air passing the open end of the spiral acts asa siphon to help pull incoming air even more quickly into the interiorof the dustcup chamber 108. The greater that the velocity is of the airentering the dustcup chamber 108, the greater is the efficiency of thesystem.

By introducing this ramped helical profile 149 to the interior contour,dirt is biased away from, the filter assembly 114, providing less dwelltime for the air/dust mixture to be in proximity to the filter assembly114. As the air/dust mixture is forced into a rapid circular motion,centrifugal forces act upon the more dense dust particles, pressing themagainst the inside walls of the dustcup chamber 108 and away from thefilter assembly 114. This reduces the effects of negative air-pressurethat might otherwise cause dust to go directly into the filter 124instead of precipitating to the base of the dustcup chamber 108. Thedistinct advantage of locating the filter 124 in the top area of thedustcup chamber 108 is to keep it out of the accumulation of dust anddebris that gather in the dustcup 106 and to maintain unimpeded air flowuntil the cup 106 is filled with dirt. There is less chance that dirtwill collect around the filter element 124 and allows easier debrisremoval from the filter surface when servicing by the operator. Afterdirt and air enter the dustcup chamber 108 and are separated bycentrifugal forces, because the air has less density than the dirt, itflows into the center area of the dustcup chamber 108 where it travelsupward, attracted by the negative pressure area proximate to the filter124. The air travels past the screen element 197 and then through theopen cell filter 124 and enters the plenum chamber 200, while minutedebris is blocked by the filter. The plenum chamber 200 is defined bythe sealed space between the cyclone module 118 and the plenum chambermember 116, and provides, a communication path for filtered air from thedustcup chamber 108 to the dustcup passageway 110. Because the plenumchamber 200 is in fluid communication with the top of the cleanpassageway 110 of the dustcup 106, filtered air proceeds to the motorintake and is ultimately routed into a HEPA filter element 199 before itis exhausted to atmosphere.

To empty the contents collected inside the dustcup 106 the operator mustpull the spring-loaded latch 178 that is located on the front side ofthe top cover 176. The latch 178 is provided with a latch projection 179that disengages from a latch projection receptacle 173 provided in thefront handle bracket 172. Once the latch projection 179 clears the latchprojection receptacle 173, the top cover 176 and the top-hinged support174 are free to pivot upwardly and are biased in this direction underinfluence of a coiled compression spring 183 nested between the fronthandle bracket 172 and the top-hinged support 174. When the top cover176 and top-hinged support 174 pivot upwardly the outer flange skirt 177of the top-hinged support 174 raises and allows the dustcup 106 to beremoved without this intended interference. The operator grasps thehandle 112 of the dustcup 106 and removes the dustcup 106 by pivoting itaway from the rear housing 102. There is slight pressure required torelease the dustcup 106 from the housing 102 as the projection 138 onplenum chamber member 116 is designed to create a slight interferencefit with the underside of the top wall in the rear housing 102 toprevent the dustcup 106 from unintentionally falling out of the unit. Toempty the dustcup 106 the operator must grasp the handle 115 attached tothe top of the plenum chamber member 116 and lift upward. The plenumchamber member 116, cyclone module 118 and filter assembly 114 will comeout from the inside of the dustcup 106 allowing easy emptying ofcontents. If cleaning of the filter 124 is also needed at this time theoperator must turn the filter receptacle 126 by grasping the cylindricallower portion 194 thereof and rotating the receptacle 126 through theminimal arc sufficient to disengage the mounting hooks 121 from theinverted channels 154. This action causes the filter assembly 114 to bereleased from the cyclone module 118. The filter assembly 114 can thenbe removed for final cleaning and servicing. After the filter assembly114 is cleaned, it can be re-installed by reversing the foregoingdirections for disassembly. The plenum/cyclone assembly can then bere-positioned inside the dustcup 106 and the cup 106 can then bereinstalled into the rear housing 102.

Because the hose connector is mounted into the pivoting cover assembly,the hose connector disengages the intake chimney 175 of the top-hingedsupport 174 when opened and re-seals to the intake chimney 175 after thecover 176 is positioned in the closed position. When the cover 176 is inthe fully closed (down) position the perimeter flange 177 resides on theoutside of the upper flange of the dustcup 106, thus holding the dustcup106 in the proper operating position without fear that the cup 106 willfall from the unit. As noted hereinbefore, the hose connector mates withthe chimney extension 175 of the top cover to provide air continuity inthe sealed system.

While the preferred embodiment of the invention has been describedabove, it will be recognized and understood that various modificationsmay be made therein and the appended claims are intended to cover allsuch modifications which may fall within the spirit and scope of theinvention.

1. A bagless vacuum cleaner system used for separation of a mixture ofdirt and air drawn into a vacuum cleaner apparatus, said bagless vacuumcleaner system comprising: a dustcup assembly removably secured to ahousing portion of said vacuum cleaner apparatus; a handle assemblyconnected to a base portion of an upstanding handle also secured to saidhousing portion of said vacuum cleaner; and a motor intake adaptorconnected to said dustcup assembly and to an air intake of a suctionmotor of said vacuum cleaner apparatus.